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Thermal Cell Barrier
Highly efficient Industry leading manufacturing system for OEM approved Encapsulated Anti-thermal propagation (ATP) pads. Encapsulated ATP pads are an advanced thermal cell barrier that delays or prevents thermal propagation from a thermal runaway event. Additionally, the thermal cell barriers optimise cell performance through compression performance and can incorporate additional layers to act as a heat transfer.
IMPROVING THE SAFETY AND PERFORMANCE OF BATTERY PACKS USING A COST-EFFICIENT CELL BARRIER DESIGNED FOR SCALE
Battery pack manufacturers, whether automotive or energy storage, face similar challenges with cell life and performance. For thermal barriers between battery cells to be completely effective, they must secure the safety of the pack and provide optimum performance and life expectancy of the cells.
Critically the barrier should delay or prevent the propagation of thermal energy from a cell in thermal runaway to its neighbouring cell. The best-performing barriers will prevent this propagation altogether allowing the cell to expend its energy without triggering a thermal event in the neighbouring cell.
Additionally, the advanced insulation materials that are ideal for this application can be dusty, fibrous and delicate. Therefore, the ideal solution must ensure that no debris or particles from the insulation material are introduced into the battery pack or assembly environment. Whilst ensuring that the delicate structure of the insulation material is not damaged and its performance compromised.
There are various ways that engineers achieve this, however, the challenge is how to produce a debris-free single piece thermal cell barrier optimised for easy assembly, in a cost-efficient production method that delivers extreme high volume.
That`s where Tecman comes in.
Tecman has developed a highly efficient manufacturing process for the manufacture of OEM approved advanced thermal cell barrier technology. The Encapsulated Anti-Thermal Propagation (ATP) Pad is an advanced single-piece thermal cell barrier manufactured in a cost-efficient production method that delivers extreme high volume.
The materials used within the Encapsulated ATP Pad can be interchanged depending on the application requirements. We can develop a bespoke solution using a combination of the clients’ specified materials or our own selection of materials.
1. Advanced Insulation Materials - The advanced insulation materials used within the Encapsulated ATP Pad provide insulation between cells using anti-thermal propagation technology to prevent thermal propagation in a thermal runaway event.
2. Encapsulation film - Provides dielectric breakdown resistance, reduces debris and aids with the handling of the pads during assembly processes.
3. Double-sided tape for bonding to cell with an adhesive liner. This bonds the pad onto the battery cell to secure it during assembly and improves the vibration and shock performance by holding the cells together adding stiffness to the pack.
The manufacturing process provides the flexibility to customise the materials of the Encapsulated ATP Pad, allowing for customer-specified materials and/or proven materials selected by Tecman`s material engineers. There is also the flexibility to incorporate additional layers to act as a heat transfer.
SUPERIOR ULTRA-LIGHTWEIGHT THERMAL INSULATION MATERIALS TO PREVENT THERMAL-RUNAWAYOur Advanced Material Engineers are constantly researching and testing innovative thermal management materials and select the most suitable materials during the development of Encapsulated ATP Pad solutions.
We can integrate customer specified materials and also guide you through the complex material selection process. Previous material recommendations for Encapsulated ATP Pads include insulation materials such as ceramics and aerogels with cutting-edge performance.
These ultra-lightweight insulation materials have the highest thermal insulation to weight value of any material available on the market. They are most effective materials for the prevention of thermal propagation in a thermal runaway event.
The compact production line has a very small footprint, making it suitable for integrating into existing clean production facilities or in a small, dedicated production space located close to the battery assembly line.
The process eliminates the need for third-party pre-conversion of the component parts enabling uninterrupted, continuous running. Each machine has the capability of producing up to 120 parts per minute.
By running continuously across shifts, it is a cost-effective, high-volume production line with a capacity to manufacture up to 36 million parts per annum.
Features
ALL IN ONE PROCESS
The machine is loaded with slit rolls of material and converts the components parts required within the Framed ATP Pad within the same manufacturing process.
CONTINUOUS PRODUCTION
The production line is one continuous manufacturing system that runs without stopping.
SMALL FOOTPRINT
The manufacturing production line is a compact unit that fits inside a small production space without needing an entire factory.
FLEXIBLE MATERIAL OPTIONS
The manufacturing process is capable of processing different materials.
MULTIPLE SIZE OPTIONS
Capable of producing multiple size parts to suit the requirement of the battery cell.
Benefits
- Eliminates the need for 3rd party conversion of component parts
- Lower material input costs
- Reduced input material complexity
- Reduced production times.
- Maximise OEE
- No downtime for roll changes
- In-line closed loop adjustments
- 100% part inspection.
- Reduces cost impact when situating in clean manufacturing area
- Allows location in close proximity to battery assembly plants.
- Flexibility to produce multiple Framed ATP Pad solutions
- Option to use customers’ specified materials or Tecman’s proven materials.
- Suitable for multiple prismatic cell solutions
- Effective for EV battery and battery storage systems.